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Commissioning Approach
Integrated Service Solutions
optimising maintenance costs
maximising plant productivity
preserving asset integrity
Conduct Plant operation
Technical assistance for O&M
Engineering
Commissioning
O&M Procurement ConstructionProcurement Construction
Plant Life Cycle
- Dynamic simulation support
- Process data reconciliation
- etc.
- Turnover Management Methodology
- Pre-commissioning
- Commissioning / start-up
- High Tech. Support
- technical assistance
- Spare Parts- M.M.(Material Management)- I.P.O.S.(Integrated Procurement outsourcing services)
TrainingTraining
Integrated operation & maintenance
IOP
Simplant®
ClassroomHands-on
Training
Side by Side
Engineering
Commissioning
O&M Procurement ConstructionProcurement Construction
Plant Life Cycle
- Dynamic simulation support
- Process data reconciliation
- etc.
- Turnover Management Methodology
- Pre-commissioning
- Commissioning / start-up
- High Tech. Support
- High tech. personnel
- Spare Parts- I.P.O.S.(Integrated Procurement outsourcing services)
TrainingTraining
optimising maintenance costs
maximising plant productivity
preserving asset integrity
Integrated operation & maintenance
IOP
Simplant®
ClassroomHands-on
Turnover Management Methodology
Preparatory works
(Home office activities)
Mechanical Completion verification
Precommissioning
Commissioning
End
Main Root Main Activities Certificates/Issues
Tool for Mesurement and reporting of Pre-Comm & Comm. Activities Progress, preparation of details (planning, etc)
Field inspections, documentation inspection (outstanding Item verification)
Inspections, Punch-list issueing, utilities comm, cleaning, flushing, blowing, chemical cleaning, non operating
adjustment, motor run-in, catalyst, internal inspection, ...
Cooling water start-up, spring hangers check, operating adjustment, purging, pressure test, ……..
Turnover management system operating manual check and
preparation
Interim Handover Certificate verification (P/L outstanding)
Ready for Commissioning Certificate
Ready for Start-up
Certificate
Performance Tests Conduct performance testsProvisional Acceptance
Certificate
Start-UpOil-In
Ready for performance test
Home Office Phase(Preparatory work)
The Turnover Management System will allow to:
• Manage QA/QC certificates• Manage Construction piping activities• Manage Construction electrical activities• Manage Construction instrument activities• Manage Construction machinery activities• Manage Construction punch lists• Have Construction progress per area• Have Construction overview progress• Have day by day reports• Manage the transaction between construction and commissioning activities• Manage pre-commissioning activities based on construction progress• Manage punch list outstanding items• Manage pre-commissioning and commissioning punch list• Manage Turnover progress and certificates• Manage mechanical completion progress, certificates and activities• Manage reinstatement progress, certificates and activities• Manage ready for pre-commissioning turnover progress, certificates and activities• Manage ready for commissioning turnover progress, certificates and activities• Manage performance test turnover progress, certificates and activities• Manage provisional acceptance turnover progress, certificates and activities • Dossiers management
Preparatory works
(Home office activities)
Tool for Measurement and reporting of Pre-Comm & Comm. Activities Progress, preparation of details (planning, etc)
Turnover management system operating manual check and
preparation
SYSTEM START-UP
PASSWORD
PASSWORD ADMINISTRATOR'S AREA
Construction
Reports &
Progress
Commissioning
Piping Electrical Instrument Machninery
Punch List Management
Mechanical Completion
Flushing
Tighteness Test
Performance Test
Provisional Test
Acceptance Test
Loop Check
Dossier Filling
Handover Management
Outstanding Item management
Preinst.
Installat.
Operation
Type 1
Type 2
Type 3
Type 4
Type 1
Type 2
Type 3
Type 4
Welding
Piping
Hydrotest
Reinstat.
Turnover Management SystemSystem layout
USER'S AREA
Turnover Management SystemSystem detail pictures
1) Main password
2) Main Menu 3) Instrument management system
4) Piping Menu 5) Punch List management system 6) Punch List Out standing Item
7) Piping Construction management system
8) Equipment Management system 9) Hydrotest Progress
• Pre-commissioning and Commissioning Manual will be supplied as a collection of precommissioning procedures; these procedures are operating instructions for the activities to be carried out during the performing of precommissioning.• The list of the procedures of the pre-commissioning manual is the following:
• Mechanical Preparation Chemical Cleaning Instructions Physical Cleaning Instructions Mechanical Restoration Machinery Run in Tightness test Electrical testing/functional tests/energising Instruments calibration and functional test Loading of chemicals Loading of catalyst Heaters drying Chemicals boil out of steam generation facilities Verification of Mechanical Completion Performance Test
Operating Manual with the following contents:Introduction
•GeneralBasis of design
•Duty of plant•Environmental conditions•Feedstocks and products specifications•Battery limit conditions•Specifications and consumption of utilities, chemicals catalysts
Process Description•Description of flow•Process Variables•Process Theory
Preparation for Initial Start-up•General•Plant Inspection•Cleaning of Piping and equipment•Specific pre-start-up operations
Start-up procedureNormal OperationNormal Shutdown ProcedureEmergency ShutdownAnalytical requirementsAttachments (P&ID’s, Class Specifications and other Project documents)
Pre-commissioning and Commissioning Manual Operating Manual
Pre-commissioning & Commissioning manualspreparation & check
Mechanical Completion verification
Field inspections, documentation inspection (outstanding Item verification)
Interim Handover Certificate verification (P/L outstanding)
In order to optimize time and costs we will:
•Verify the mechanical completion Punch list outstanding items via field inspections and
certificates control and registration;
•Plan the pre-commissioning and commissioning activities based on the real situation
PrecommissioningInspections, Punch-list issueing, utilities comm, cleaning,
flushing, blowing, chemical cleaning, non operating adjustment, motor run-in, catalyst, internal inspection, ...
Ready for Commissioning Certificate
inspectionpunch-listing
utilities commissioningcleaningflushingblowing
chemical cleaningnon operating adjustment
motor run invessel loading
internalscatalyst
desiccantresins
packingdrying
machinery alignmentinstrument calibration
loopcheckingorifice plates installationsafety valves bench test
tightness test
Commissioning Cooling water start-up, spring hangers check, operating adjustment, purging, pressure test, ……..
Ready for Start-up certificate
Check all spring hangersStart up cooling water system,which may include Chlorinator
Run in pumps on water,where possible, and establish CirculationStart up compressors,where possible,on nitrogen and air
Activate the inert gas systemLight flare pilots, if used, and activate flare purges at the extremity of lines in the unit
Turn on the fuel gas system to process burnersStart up the fuel oil system to process burners
Boil out the steam generator (if it has not been chemically cleaned during pre-commissioning) Commission water treating facilities
Implement steam system andsteam trcing before insulation is checkedActivate condensate systems
Purge equipment, where requiredPerform operational pressure test
Run required vcuum testsDry out refractories and heaters and special lines
Reactor system dry outCheck waste-treatment area for operation
Circulate chemical solutions where requiredActivate catalysts where requiredPrepare for and circulate test oil
Recheck all trip circuits and their bypassesPractice normal and emergency shutdowns. If time allows, practice restarts
Performance TestsConduct performance tests
Provisional Acceptance Certificate
Performance Tests Procedures preparation and validation
Systems preparation for performance tests
Conduct performance test in order to meet process guaranteed figures
Start-upOil-in Ready for Performance test
Introduce feed at low flow rate
Adjust temperatures, pressures, levels and flows
Route off-specifications material to the designated areas
When the product reaches the specifications route it to storage
Increase slowly the feed rate to the Unit until the designed value.
Pre-commissioning & Commissioning typical organization chart
C o n s tru c tionO rg a n isa tion
S h iftS u p e rv iso rs
P a n e lO p e ra to rs
P ro ce ss U n itC o m m iss io n in gS u p erin te nd e n t
S h iftS u p e rv iso rs
P a n e lO p e ra to rs
U tility /O ffs iteC o m m iss io n in gS u p erin te nd e n t
In s trum e ntE le c trica l
M a ch in e ryM e ch a n ica l
L a b o ur
P ip ing
S u p e rv iso rs V e n d o r'sS p e c ia list
Q A /Q CM a n a g er
S afe tyM a n a g er
C o m m iss io n ingM a n a g er
S ite Re s id en t M an a g er O w n e r/M a n a g ingC o n trac t In te rfa ce
Comerint
Main Contractor
Comerint Organisation Chart
F O R IN DIn d u s tria l T ra in ing
E U C o nsu lta n cy
A V V IM PC o m m is s io n ing
S ta rt-upT e ch n ica l A s s is ta n ce
F O R P E TT ra in in g O il& G as
S IM P R OP ro ce ss S im u la tion
S E P C OS e rv ice s to E P C C o n tra c to rs
G E IM PP la n t O p era tion
T e ch n ica l A s s is ta n ce
A T T O PO p e ra tion
C o n tra c ting
B D ITIta ly
B D IN TIn te rn a tio n a l
B u s in e ss D e ve lo p m e nt
M a rke ting
S p a re P a rtsP ro cu re m e nt
C O M A PC o m m e rc ia l
A M M C OA d m in is tra tio n a n d C o n tro l
P E R O R GH u m a n R e s o u rce
T E C N OT e ch n ica l D e ve lo p m e nt
A D L
EPC CONTRACTORS OWNERS
OPERATIONSOPERATIONS
MAINTENANCEMAINTENANCE
CONSULTANCY SERVICES CONSULTANCY SERVICES
TRAINING AND HRD (CTS)TRAINING AND HRD (CTS)
ENGINEERING AND TECHNICAL DEPT. SUPPORT SERVICES (SIMULATION)
ENGINEERING AND TECHNICAL DEPT. SUPPORT SERVICES (SIMULATION)
COMMISSIONINGCOMMISSIONING
START-UPSTART-UP
Comerint services during Plant Life Cycle